CN101489656B - Hot gas filtration fabrics with silica and flame resistant fibers - Google Patents
Hot gas filtration fabrics with silica and flame resistant fibers Download PDFInfo
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- CN101489656B CN101489656B CN2007800262341A CN200780026234A CN101489656B CN 101489656 B CN101489656 B CN 101489656B CN 2007800262341 A CN2007800262341 A CN 2007800262341A CN 200780026234 A CN200780026234 A CN 200780026234A CN 101489656 B CN101489656 B CN 101489656B
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- fibre
- filter
- fiber
- fire resistance
- amorphous silica
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/02—Particle separators, e.g. dust precipitators, having hollow filters made of flexible material
- B01D46/04—Cleaning filters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/66—Regeneration of the filtering material or filter elements inside the filter
- B01D46/70—Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter
- B01D46/71—Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter with pressurised gas, e.g. pulsed air
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2273/00—Operation of filters specially adapted for separating dispersed particles from gases or vapours
- B01D2273/20—High temperature filtration
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Filtering Materials (AREA)
- Woven Fabrics (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
- Inorganic Fibers (AREA)
Abstract
Hot gas filtration fabrics for bag filters can be made using fibers that include high silica fibers and at least one FR fiber. The fabrics can be made using these fibers by needling and/or water jet entanglement. The fabrics may be treated with binders with or without additives to enhance mechanical properties or to impart other characteristics such as gas adsorption. Certain non- woven fabrics made according to the invention have improved high temperatures filtration capabilities and mechanical properties.
Description
Statement about related application
The application requires the priority of the U.S. Provisional Patent Application 60/808,747 of submission on May 26th, 2006, and the whole content of the document is incorporated this paper by reference into.The application also is involved in the PCT patent application PCT/US2005/043173 that submitted on November 30th, 2005, and the whole content of the document is also incorporated this paper by reference into.
Invention field
Relate generally to filter of the present invention (filter).More particularly, the present invention relates to weaving filter device (non-woven filter), it is fire-retardant and can be made by the fibre blend that comprises amorphous silica fibres and at least a fire-retardant (FR) fiber.
Background of invention
Thereby usually carry out fluid for example gas filtration with from this air-flow except the noxious emission of degranulation or irrelevant impurity restriction impurity in the environment, or be circulated back in the related process.Usually wish that so that the surface area maximization that can be used for filtering so that remove a large amount of undesirable pollutants from fluid streams the operation pressure reduction that caused by described filter is kept to realize the long life and surface strain is minimized in the lowland as far as possible simultaneously.
In being commonly referred to a kind of filtered version of interception, the effect of filter medium performance screen cloth, it mechanically holds back the particle greater than the intrinsic aperture of this medium.Remove larger particles by the perforate in the filter medium from fluid streams, particle produces in accumulation over each other and one after the other removes more short grained filter cake simultaneously.
More particularly, in so-called " bag filter (baghouse filter) ", when passing filter medium, steering current from this air-flow, removes granular materials.In typical an application, filter medium has substantially canular tubular type configuration, wherein on the outside of particle deposition at this sleeve pipe of air-flow through arranging so that will just being filtered.In this class is used, periodically clean this medium by filter medium being experienced pulse adverse current (pulsed reverse flow), this pulse adverse current is used for removing the granular materials that is filtered in order to collect in the bottom of this bag type filtering structure from the outside of sleeve pipe.United States Patent (USP) 4,983,434 (incorporating by reference this paper into) for example understood the stacked body of filter of bag filter structure and prior art.
The most frequently used fiber that is used for hot gas filtration is PETG (PET), acrylic resin, meta-aromatic polyamide, polyimides, polyphenylene sulfide and glass fibre, and they use as fibre blend usually.United States Patent (USP) 4,295,868 have described and have scribbled metal oxide to improve the silicate glasses fiber base fabric of fibre strength.This patent is mentioned and is comprised 95% or more SiO
2Glass fibre think too crisp and can not be used as filter.WO 86/00570 has described the stratiform filtration fabrics that comprises independent glass layer and one or more organic fiber layers.Employed glass fibre can be made by C-glass fibre, E-glass fibre or S-glass fibre.WO87/01655 has described and has comprised for example filter medium of the layer of glass of high temperature fiber, and this layer is attached to by the high temperature fiber fabric made of glass fibre for example, thereby obtains good flex stiffiness.Following patent documentation has been described the use of glass fibre, but the type of employed glass fibre: U.S.5 in the unqualified manufacturing fiber, 713,972, U.S.6,340,379, WO 03/095067, WO 99/47236, U.S. patent application 2002/0023874,2002/0023419,2003/0101866,2004/0163540.
Some patents have been described by comprising adsorbent for example activated carbon, zeolite or fiber itself made the trial that porous improves the pollutant adsorption capacity of fiber.Therefore, U.S. Patent application 2004/0163540 and WO 03/090900 have described use activated carbon or zeolite, and U.S. Patent application 2004/0197552 has been described manufacturing silicon dioxide fibre based fabric and process to produce hole at fiber surface with inorganic mixture.
The fabric that need to have improved high temperature filtration ability and mechanical performance.
Brief summary of the invention
Be surprisingly found out that, can use non-woven manufacturing technology that silicon dioxide fibre is mixed with the conventional fibre that is used for bag filter, have the heat resistance of raising and the improved filtration fabrics of lower cost in many cases with preparation.Based on these discoveries, in an exemplary, the present invention can provide the nonwoven filter media that comprises silicon dioxide fibre (non-woven filter media), or the bag filter of being made by this filter medium.This filter medium can preferably use the manufacturing of routine needling technology, and preferred by using inner woven scrim (scrim) to strengthen.This supatex fabric can be fire-retardant and it can be made by the fibre blend that comprises amorphous silica fibres and at least a fiber that is made of fire-retardant (FR) fiber.
Described supatex fabric can have (1) enough mechanical strengths to bear the pressure in use and multiple deflection cycle period generation, (2) to the long-term tolerance of harsh chemical product, (3) be not subjected to the ability of the continued operation temperature effect of (900 °F) up to 482 ℃, (4) to the tolerance of good spark (hot spark), (5) under serviceability temperature less than about 1% shrinkage factor, (6) high filter efficiency, and (7) are to by the tolerance of microbial attack.
Described supatex fabric can comprise the silicon dioxide fibre of the about 80wt% of about 20-, with one or more FR fibers of the about 80wt% of about 20-, this FR fiber is selected from modified polyacrylonitrile, the polyester of phosphorous heterocycle pentane (phosphalane), melamine, meta-aromatic polyamide (meta aramid), contraposition aromatic polyamide (para aramid), polybenzimidazoles, polyimides, polyamidoimide, the polyacrylonitrile of partial oxidation, novoloid (contain linear phenol-aldehyde resin and be no less than 85% phenolic fibre), poly-(to phenylene Ben Bing Er oxazole), poly-(to the phenylene benzothiazole), polyphenylene sulfide, anti-flaming viscose artificial silk; The viscose rayon yarn of silicon aluminate improved silica, cellulosics, polyether-ether-ketone, polyketone, PEI, scribble the natural or synthetic fibers of FR resin or their mixture.
Other exemplary of the present invention relates to the purposes of these fabric/filters in the requirement for height industrial filtration applications, described filtration application includes but not limited to, the impulse jet filtration system of using in pitch, cement, Industrial Boiler and industrial furnace, generating and the incineration of waste market and contra-injection filtration system.Therefore, in another exemplary, the invention provides the method for filtering particle from fluid, it comprises: the filter that comprises silicon dioxide fibre (a) is provided; (b) at negative pressure or direct draught described flow is crossed the become fabric retardance of being made by this silicon dioxide fibre or be detained of this filter so that described particle.
Attendant advantages of the present invention will partly provide in description subsequently, and partly will describe obviously from this, maybe can arrive by practice knowledge of the present invention.Advantage of the present invention will realize with combination by the key element of especially pointing out in appended claims and obtain.According to what advocate, should be appreciated that only exemplary and explanat being not intended to limit the invention of above general introduction and following detailed description.
The accompanying drawing summary
The accompanying drawing that is attached in this specification and consists of this specification part for example understands exemplary more of the present invention and is used for explaining principle of the present invention together with this description.
Fig. 1 is the graphical representation of exemplary that disposes according to the pulse adverse current bag filter that an exemplary filter medium of the present invention of the present invention especially is fit to.
Fig. 2 shows the further details according to an exemplary of the present invention exemplary filter media as shown in Figure 1.
Fig. 3 shows the potential filtration application according to the filtering material of the present invention of exemplary of the present invention.
Fig. 4 show according to an exemplary of the present invention as shown in Figure 1 from the fluid method of filtering particle the hot gas for example.
Detailed Description Of The Invention
By use separately defined below have the silicon dioxide fibre of high silicon dioxide content and preferably fire-retardant at least/anti-combustion (FR) thermoplastic polymer fibers (FR fiber) make fabric of the present invention.
Anti-flammability is defined as by ASTM " performance of material, performance is having or is not removing subsequently in the situation of this burning things which may cause a fire disaster after using flame or nonflame burning things which may cause a fire disaster by this, flame combustion is prevented from, and stops or inhibition ".Flame-retardant materials can be polymer, fiber or fabric.Fire retardant is defined as " chemicals that is used for giving anti-flammability " by ASTM.
The weight percent of the silicon dioxide fibre in the non-woven material of the present invention compatibly is about at least 5,10,20,30 or 40wt% of this material, and less than about 95,90,80,70 or 60wt%.Similarly, the weight percent of the FR fiber in this material compatibly is about at least 5,10,20,30 or 40wt% of this material, and less than about 95,90,80,70 or 60wt%.Preferred, be still in the exemplary embodiment, this material comprises:
The approximately about 70wt% silicon dioxide fibre of 20-and the approximately about 80wt%FR fiber of 30-;
The approximately about 65wt% silicon dioxide fibre of 30-and the approximately about 70wt%FR fiber of 35-; Or
The approximately about 60wt% silicon dioxide fibre of 40-and the approximately about 60wt%FR fiber of 40-.
According to an exemplary, described nonwoven filter media can comprise the about 95wt% silicon dioxide fibre of about 5-and about one or more FR fibers of the about 95wt% of 5-.In addition, according to another exemplary, described nonwoven filter media can further comprise two peripheral layers (peripheral layer) and internal layer, and wherein said internal layer comprises scrim, and described peripheral layer comprises mixed uniformly silicon dioxide fibre and FR fiber.
According to another exemplary, described nonwoven filter media can comprise the about 80wt% silicon dioxide fibre of about 20-and about one or more FR fibers of the about 80wt% of 20-, and this FR fiber is selected from modified polyacrylonitrile, the polyester of phosphorous heterocycle pentane, melamine, meta-aromatic polyamide, the contraposition aromatic polyamide, polybenzimidazoles, polyimides, polyamidoimide, the polyacrylonitrile of partial oxidation, contain linear phenol-aldehyde resin and be no less than 85% phenolic fibre, poly-(to phenylene Ben Bing Er oxazole), poly-(to the phenylene benzothiazole), polyphenylene sulfide, anti-flaming viscose artificial silk; The viscose rayon yarn of silicon aluminate improved silica, cellulosics, polyether-ether-ketone, polyketone, PEI, scribble the natural or synthetic fibers of FR resin or their mixture.
According to another exemplary, nonwoven filter media is made by the fibre blend that comprises amorphous silica fibres and fire-retardant (FR) fiber.This mixture can comprise the about 65wt% amorphous silica fibres of about 5-and about one or more FR fibers of the about 95wt% of 35-.
In an especially preferred exemplary, by a plurality of combed accumulation body (carded stack) the preparation fabrics of acupuncture manipulation by fiber.Each has combed accumulation body can only comprise a kind of specific fiber, or the specific mixture of fiber, but in a preferred exemplary, and each has been combed accumulation body and has comprised and evenly be blended in each in the described material and combed all fibres in the accumulation body.In an exemplary, there are at least two fiber accumulations bodies by the woven scrim isolation, this woven scrim becomes in acupuncture manipulation and is combined with described accumulation body.This woven scrim can be by any can standing the desired physics of described material (for example glass fibre) to be required and in about any scrim of making of the material of 2.5osy (ounce per square yard) preferably aspect the weight.
The description of high silica fiber (high silica fiber)
Practice of the present invention comprises the fibre blend that comprises amorphous silica fibres and at least one class FR fiber.With more detailed the illustrating, then this fibre blend can be used for being formed for multi-purpose fabric, supatex fabric and Woven fabric such as this paper.According to an exemplary, the filter that is used for the deposited particles material is made by the supatex fabric with described fibre blend.
Usually, improve any amorphous silica fibres of charing intensity (charstrength) in the time of can using in adding fibre blend to.Term " silica " refers to multiple crystallization and the naturally occurring silica of amorphous form.When the basic structure (it is that two tetrahedrons are common that the silicon tetrahedron satisfies each oxygen atom through arrangement) of described molecule repeats with symmetry, think that silica is crystallization.If described molecule lacks crystalline texture, think that then silica is unbodied.This SiO
2Molecule is random connection, does not form repeat patterns.Crystalline silica is undesirable, has the health effect that the fragment that can suck size is associated because be broken into its fragility crystalline texture.
Amorphous silica fibres is silica (SiO
2) at least about high-load silicon dioxide fibre of 90wt% of content, based on the gross weight of this high silica fiber.In one or more exemplary, silicon dioxide fibre has at least approximately 65wt%, 70wt%, 75wt%, 85wt%, 90wt%, the dioxide-containing silica of 95wt% and even 95wt%.For example, high silica fiber can comprise about 98wt% silica, and remainder mainly comprises aluminium oxide.In some exemplary, the amount of halogen is less than about 120 ppm by weight in the high silica fiber.
According to an exemplary, nonwoven filter media comprises the silicon dioxide fibre with about at least 70wt% silica.This silica can be amorphous silica.According to another exemplary, nonwoven filter media has the silicon dioxide fibre that comprises about at least 85wt% amorphous silica.
Preferably, in most of exemplary, silicon dioxide fibre is basically unbodied.Although described fiber can comprise certain crystalline material, the degree of crystallinity of significant quantity is not preferred.The silicon dioxide fibre that is fit to is commercially available, for example from Polotsk-Steklovolokno, Belarus, by their U.S. agent merchant at Sparks, the TMS of Nevada.
In an exemplary, the parent material composition that is used for high silica fiber is: 72-77%SiO
2, 2.5%B, 3.5%Al
2O
3, 20-25%Na
2O, 0.01-1.0%CoO and 0.01-0.5%SO
3, all be weight percent, based on the gross weight of said composition.Said composition is 1480 ± 10 ℃ of lower meltings and form continuous fiber.Then the hot sulfuric acid of working concentration 2N under 98 ± 2 ℃ temperature with 60 minutes this fiber of time of staying leaching.Then wash this fiber with running water until the pH value is about 3-5.In this exemplary, the fiber of gained has the SiO of about 95-99wt% ± 1
2Content, remainder mainly are Al
2O
3
, be described in 393 (' 393 patents) in Russian Patent No. 2,165 for the manufacture of the vagcor composition (high silica glasscomposition) of high silica fiber and method, the document is incorporated this paper accordingly by reference into.High silica fiber that should ' 393 patents is described as having the lower coefficient of variation aspect the intensity of basic long filament, and this generation makes the stable possibility of the strength characteristics of gained fiber, particularly at high temperature the use procedure.Following description about high silica fiber selects from this ' 393 patents only be used for illustrative purpose and should not be construed as restriction the present invention.
In one or more exemplary, comprise SiO
2, Al
2O
3And Na
2The glass composition of O also comprises CoO and SO in following ratio (quality percentage)
3:
Al
2O
3：2.5-3.5
Na
2O：20-25
CoO：0.01-1.0
SO
3：0.01-1.0
SiO
2: all the other.
This glass can comprise at least a CaO of being selected from, MgO, ZrO by following amount (quality percentage)
2, TiO
2, Fe
2O
3Oxide:
CaO：0.01-0.5
MgO：0.01-0.5
TiO
2：0.01-0.1
Fe
2O
3：0.01-0.5
ZrO
2：0.01-0.5。
In another exemplary, except SiO
2And Al
2O
3Outside described high temperature silica fiber also comprise CoO and SO in following ratio (quality percentage)
3:
SiO
2：94-96
Al
2O
3：3-4
Na
2O：0.01-1.0
CoO：0.01-1.0
SO
3：0.01-1.0。
Described silicon dioxide fibre can also comprise at least a CaO of being selected from, MgO, TiO by following amount (quality percentage)
2, Fe
2O
3, ZrO
2Oxide:
CaO：0.01-0.5
MgO：0.01-0.5
TiO
2：0.01-0.1
Fe
2O
3：0.01-0.5
ZrO
2：0.01-0.5。
In an exemplary, described silicon dioxide fibre is substantially free of any coating of metal oxides.The diameter of described silicon dioxide fibre can be about 5.6 microns-about 12.6 microns and in an exemplary, this diameter is about 8 microns.The length of described silicon dioxide fibre can for about 50 millimeters-about 125 millimeters and, in an exemplary, this length is about 75 millimeters, (can obtain more to lack and longer fiber by the shearing length of regulating fiber, but use usually impracticable to acupuncture).
The preparation of glass fibre
Glass fibre preparation according to above-mentioned Russian Patent No. 2,165,393 embodiment 1-3 is described below: in order to prepare the continuous filament yarn glass fibre with the composition that proposes, prepare to comprise (quality percentage) SiO
2: 72.39, Al
2O
3: 2.5, Na
2O:25, CoO:0.01, SO
3: 0.1 container.Pack in the stove this container and melting under 1480 ± 10 ℃ temperature.From this melten glass material, use 400-hole glass formation aggregation (aggregates) under 1260 ± 50 ℃ temperature, to form diameter and be the continuous glass fibre of 6-9 micron.The gained fiber has the intensity of 1030Mpa and the surface tension of 0.318H/m.The hot sulfuric acid solution of working concentration 2N (about 10%) carries out leaching under 98 ± 2 ℃ temperature.The time of contact of fiber in this solution is 60 minutes.Rinse out leaching solution with running water from described fiber by leaching, product and starching residue are until the pH value is 3-5.Carry out the last washing of this fiber and simultaneously dehydration with deionized water.
Preparation, its processing and the leaching of embodiment 2 and 3 glass composition are similar to embodiment 1.Table 1 and 2 provides this glass composition, the characteristic of molten product, the characteristic of the characteristic of processing and this glass and silicon dioxide fibre.Table 3 provides the strength characteristics of earth silicon material after being exposed in 1000 ℃.
Table 1 also provides the data of confirming the following fact to 3: cobalt and SO
3Introducing glass composition increases the inhomogeneities of glass substance, reduces its surface tension, reduce fiber during processing fragility and increase in addition silicon dioxide fibre and based on the stability of the technical characteristic of the resulting materials of this fiber.
Table 1
The surface tension of the melten glass of * obtaining as prototype is 0.228N/m.
Table 2
Table 3
Earth silicon material fracture load after 1000 ℃ of lower hot-working
Following table 4 and 5 shows multiple glass fiber compound, can find out by Russian Patent No. 2,165 from these compositions, and the silicon dioxide fibre of 393 instructions and all other fiberglass type differences are to exist trace CoO and SO
3
Table 4
Table 5
The FR fiber
Discuss amorphous silica component of the present invention, next will discuss additive fiber.In the following discussion, the use of term " silicon dioxide fibre " should be understood to refer to comprise those fibers of amorphous (opposite with crystallization) silica.
The amount of silicon dioxide fibre can change according to employed FR fiber in the fibre blend of amorphous silica and FR fiber.In an exemplary, the amount of silicon dioxide fibre is the about 65wt% of about 5-in this mixture, based on the gross weight of this mixture.In another exemplary, the amount of silicon dioxide fibre is the about 50wt% of about 15-in this mixture.In another exemplary, the amount of silicon dioxide fibre is the about 30wt% of about 20-in this mixture.Remaining fiber comprises the non-amorphous fiber of necessary amount in this mixture, i.e. FR fiber is to equal 100wt%.
In other words, fabric of the present invention also generally includes at least a fire-retardant or anti-combustion (FR) fiber and term as used herein FR comprises this two class.Known multiple FR fiber in this area.The FR fiber that adopts in the fabric of the present invention can be intrinsic fire resistance fibre or the fiber that scribbles the FR resin (natural or synthetic fibers).Intrinsic fire resistance fibre is not applied, but has the FR component in the structural chemistry of introducing this fiber.Term as used herein FR fiber had both comprised intrinsic anti-combustion and fire resistance fibre and be not inherently anti-combustion or fire-retardant but scribble the fiber of FR resin.Therefore, for instance, the polypropylene fibre that scribbles the FR resin will be the FR polypropylene fibre.
The example of the intrinsic fiber of anti-the combustion comprise have phosphorus-containing groups, the polymer fiber of amine, modified aluminosilicate or halogen-containing group.The instantiation of intrinsic fire resistance fibre comprise melamine, meta-aromatic polyamide, contraposition aromatic polyamide, polybenzimidazoles, polyimides, aromatic polyimide, polyamidoimide, partial oxidation polyacrylonitrile, contain linear phenol-aldehyde resin and be no less than 85% phenolic fibre, poly-(to phenylene Ben Bing Er oxazole), poly-(to the phenylene benzothiazole), polyphenylene sulfide, anti-flaming viscose artificial silk; (for example comprise 30% alumino-silicate improved silica SiO
2+ Al
2O
3Viscose rayon yarn base fiber), polyether-ether-ketone, polyketone, PEI and their combination.
Melamine comprises those that sold with trade name Basofil by McKinnon-Land-Moran LLC.Meta-aromatic polyamide comprises poly, for example by E.I.Du Pont de Nemours and Co. with trade name
Sell, by TeijinLimited with
With
That sell and by Russian State Complex with
Sell.The contraposition aromatic polyamide comprises PPTA), for example by E.I.Du Pont de Nemours and Co. with trade name
Sell, and poly-(diphenyl ether contraposition aromatic polyamide), for example by Teijin Limited with trade name
Sell, and by Acordis with trade name
That sell and FENYLENE
(Russian State Complex).
Polybenzimidazoles is sold with trade name PBI by Hoechst Celanese Acetate LLC.Polyimides comprises by Inspec Fibers with trade name P
With by E.I.Du Pontde Nemours and Co with
Those that sell.Polyamidoimide for example comprises by Rhone-Poulenc with trade name
Those that sell.The polyacrylonitrile of partial oxidation for example comprises, by Fortafil Fibers Inc. with trade name FORTAFIL
By Textron Inc. with
By Zoltek Corp. with
By SGL Technik with
By American Fibers and Fabrics with
With by TohoRayon Corp. with
Those that sell.
Contain linear phenol-aldehyde resin and be no less than 85% phenolic fibre and for example comprise, the P-F novolaks, for example by Gun Ei Chemical Industry Co. with trade name
Sell.Poly-(to phenylene Ben Bing Er oxazole) (PBO) by Toyobo Co. with trade name
Sell.Poly-(to the phenylene benzothiazole) also claims PBT.Polyphenylene sulfide (PPS) comprises by AmericanFibers and Fabrics with trade name
By Toray Industries Inc. with TORAY
By Kureha Chemical Industry Co. with
With by Toyobo Co. with
Those that sell.
Anti-flaming viscose artificial silk for example comprises, by Lenzing A.G. with trade name
With by Sateri Oy Finland with
Those that sell.Polyether-ether-ketone (PEEK) for example comprises, by Zyex Ltd. with trade name
The polyether-ether-ketone of selling.Polyketone (PEK) for example comprises, by BASF with trade name
The polyketone of selling.PEI (PEI) for example comprises, by General Electric Co. with trade name
The PEI of selling.
Modified acrylic fibre by acrylonitrile and other material for example the copolymer of vinyl chloride, vinylidene chloride or bromine ethene make.Can add fire proofing for example antimony oxide with further raising firing resistance.The modified acrylic fibre that uses among the present invention is made with name of product KANECARON PBX and PROTEX-M, PROTEX-G, PROTEX-S and PROTEX-PBX by Kaneka.The product of back comprises at least 75% acrylonitrile-vinylidene chloride copolymer.The SEFPLUS of Solutia also is the modified acrylic fibre with fire resistance.
Other example that is suitable for the intrinsic FR fiber of fabric of the present invention comprises the polyester of phosphorous heterocycle pentane, for example by KoSa with trade mark TREVIRA
Fiber or
The polyester that the PLUS fiber is sold.
Other chlorinated polymer fiber usefully, for example by Rhovyl S.A. with trade name
L9S ﹠amp; ZCS,
L9F,
L9R,
MPS, by Thueringische with
By Kureha Chemical Industry Co. with
By Teijin Ltd. with
By Toyo Chemical Co. with
By Pittsfield Weaving with
By KurehaChemical Industry Co. with
By Fibrasomni, S.A.de C.V. is with OMNI-
Those that sell, and their combination.For example polytetrafluoroethylene (PTFE) (PTFE), poly-(ethylene-chlorinated) are (E-CTFE), polyvinylidene fluoride (PVDF), poly-perfluoro alkoxy (PFA) and poly-ethylene fluoride-propylene (FEP) and their combination also be useful for the fluorinated polymer fiber.
Fabric of the present invention comprises the mixture of high silica fiber and FR fiber.This high silica fiber can be about about 99wt% of 1wt%-in described mixture, also be the same concerning the FR fiber, reaches to amount to 100%.
Natural or the synthetic fibers that scribble the FR resin also can be used for fabric of the present invention.The fiber that is fit to that scribbles the FR resin comprises that this resin wherein comprises in the following material one or more those: phosphorus, phosphorus compound, red phosphorus, phosphide and phosphorus complex; Amines, boric acid, bromide, ureaformaldehyde compound, phosphate-carbamide compound, ammonium sulfate or halogen radical compound.Non-resin coating such as metal coating are not preferred to the present invention, because they are easy to peel off after the continuous use of product.Commercially available FR resin is by Spartanburg, and the Glotex Chemicals of S.C is with trade name GUARDEX
With
Sell.
The mode that described resin is coated onto on the fiber is not particularly limited.In an exemplary, the FR resin is can be as the flowing product of spray.In another exemplary, the FR resin is the solid that can be used as on the hot melt goods paint fiber, or as the pressed powder that is then fused into described fiber.In an exemplary, based on the gross weight of applied fiber, press the amount of the about 25wt% of about 6-with on the described fiber of FR resin paint.
The amount of applied FR fiber can change in the described mixture, but is the about 95wt% of about 35-, based on the gross weight of this mixture.In an exemplary, the amount of applied FR fiber is the about 90wt% of about 40-in the described mixture.In another embodiment, the amount of applied FR fiber is the about 85wt% of about 45-in the described mixture.
The danier of FR fiber is the about 15dpf of about 1.5-(filament denier).FR fiber listed earlier should not be construed as restriction the present invention practice but is used for illustrating the following fact: any known FR fiber can use and is used for practice of the present invention with amorphous silica fibres.Therefore, fiber type comprises multifilament and the monofilament yarn with multiple cross section and shape, and usually by the fibrillating fibre yarn of cutting film slat or long narrow material for making clothes and making.
Fabric of the present invention can further comprise one or more non-FR fibers.This non-FR fiber can be synthetic or natural fiber.The non-FR synthetic fibers that are fit to comprise for example PETG (PET) of polyester; Cellulosics, for example artificial silk and/or Lyocell fiber; Nylon; Polyolefin is polypropylene fibre for example; Acrylic resin; Melamine and their combination.Lyocell fiber is the general classification of the cellulose fibre of solvent spinning.These fibers can title
Be purchased.Natural fiber comprises flax, mestha, hemp, cotton and wool.In an exemplary, non-FR fiber is used for improving some characteristic for example bulkiness, rebound performance or elasticity, hot strength and warmth retention property.
Described fibre blend comprises amorphous silica fibres and at least a FR fiber.Therefore, the present invention is presented as and comprises amorphous silica fibres, FR fiber, randomly additional FR fiber and the fibre blend of one or more non-FR fibers randomly.In an exemplary, described fibre blend comprises: modified acrylic fibre; Cellulose fibre, Lyocell fiber and amorphous silica fibres.
In another exemplary, described fibre blend also comprises more than a kind of FR fiber.In another exemplary, described fibre blend comprises amorphous silica fibres, modified acrylic fibre and VISIL.In another exemplary, fibre blend comprises: modified acrylic fibre, FR rayon fiber and amorphous silica fibres.
In another exemplary, fibre blend comprises modified acrylic fibre, VISIL (FR viscose rayon yarn) fiber, amorphous silica fibres and FR polypropylene fibre.The amount of every kind of component can change; Yet, when preparing needle punched fabric by the mixture that comprises about 40wt% modified polyacrylonitrile, about 40wt%VISIL, about 15wt% amorphous silica and about 5wt%FR polypropylene fibre, obtain favourable charing intensity.
Supatex fabric of the present invention can be by preparing fibroreticulate fibre machinery interlocking.This mechanical interlocking is preferably realized via combing/acupuncture manipulation.The needle-punching method of preparation supatex fabric is as known in the art.In an exemplary, supatex fabric (sometimes being called felt formula fabric) can followingly be constructed: the fibre blend and then make its dry-laying/air lay to moving conveyor of weighing.Can regulate the speed of this conveyer belt so that required felt formula fabric weight (batt weight) to be provided.Needing machine is passed in the supply of multilayer felt formula fabric, there, drive the described layer of crochet hook process so that entanglement to be provided.
There are some other known methods for the preparation of supatex fabric, comprise Hydroentangled (water thorn), heat bonding (hot rolling formula and/or hot air type (though-air)), latex bonded or adhesive adhesion technique.Water thorn method is similar to acupuncture, and difference is to use water jet to replace crochet hook to make fibre matting.Heat bonding requires certain type thermoplastic fibre or powder to serve as binding agent.So-called supatex fabric comprises all versions at this.
Suitable supatex fabric of the present invention has the felt formula fabric weight greater than about 2.25oz./sq.yd. (osy).In an exemplary, felt formula fabric weight is the about 20osy of about 2.25osy-.In an exemplary, with the fiber combing.Then, conveyer belt moves on to the zone that wherein can randomly sprayed on material be added into non-woven felt formula fabric.For example, the FR resin can be sprayed on the non-woven felt formula fabric as latex.In an exemplary, conveyer belt is porous, and excessive latex sprayed on material drips and can collect in order to re-use afterwards by this conveyer belt.After optional spraying, fibre blend is transported to drier or baking oven.Can this fiber be transported to needing machine by conveyer belt, there, with the fibre machinery ground of this felt formula fabric orientation and interlocking to form supatex fabric.
Bag filter is used
With reference to Fig. 1, wherein diagram shows the representative pocket type filtration device structure that uses with filter medium of the present invention according to an exemplary.This class bag filter structure 10 is generally used for requiring the commercial Application of filtering particulate material 16 from input fluid material stream 20A.As shown, input fluid material stream 20A enters filter chamber 12,, has arranged one or more substantially tubular cannula-like filter bags 14 within it.This filter bag 14 can be sealed filter layer stack structure 18 and cage construction 26 separately.This filter bag 14 can be supported by tube sheet 28.
By crossing over filter medium or structure 10 generation pressure reduction, this input fluid material stream 20A for example hot gas such as steam can flow through the outer surface of this filter bag 14, and granular materials 16 is removed from input fluid material stream 20A as deposition and leans against material 16 on the filter medium 10.Then filtered fluid streams 20B can leave this filter chamber 12 at delivery channel 24.As mentioned above, an advantage of filter bag 14 constructed in accordance is heat resistance and anti-burning or Carbonizations that they have raising.This filter bag 14 is preferably made by supatex fabric, this supatex fabric be anti-combustion and made by the fibre blend that comprises amorphous silica fibres and at least a fiber that is consisted of by fire-retardant (FR) fiber.
Usually, can pursue particle-removing material 16 from the outside of this filter bag 14 by the pulse adverse current that periodically makes each filter bag 14 experience fluid 20C.Under the pulse adverse current of this fluid 20C that passes through filter medium 10, impel granular materials 16 (being commonly referred to filter cake) to break away from from the outside of each filter bag 14, and be collected in the bottom (being called hopper 22) of filter chamber 12.
The bag type filtering medium 10 of implementing the principle of the invention can be assembled into the filter bag 14 shown in Fig. 1.For this type of application, filter medium 10 can form flat sheet, and wherein opposite edges engage and form the pipe of terminal perforate.Then this pipe can at one end seal and form cannula-like sack 14, as shown in Figure 1.Use for other, filter medium can use by its smooth form (not shown), or uses by the form of tubes of terminal perforate.
Referring now to Fig. 2, this accompanying drawing shows an exemplary according to the present invention in the further details of exemplary filter media shown in Figure 1 10.Structure 26 shown in Figure 2,14A, 202 and 14B between the interval be exaggerated to show details.
This inside scrim 202 can be made by weaving material (woven material).In an exemplary, two peripheral layer 14A, 14B of the fiber of filter of the present invention are woven scrim 202 isolation, and this scrim 202 can become by acupuncture manipulation and be combined with these two peripheral layer 14A, 14B.This woven scrim 202 can be by any can standing the desired physics of described material (for example glass fibre) to be required and in about any scrim of making of the material of 2.5osy (ounce per square yard) preferably aspect the weight.This peripheral layer 14A, 14B is preferably made by supatex fabric, this supatex fabric be anti-combustion and made by the fibre blend that comprises amorphous silica fibres and at least a fiber that is consisted of by fire-retardant (FR) fiber.
Referring now to Fig. 3, this accompanying drawing shows the potential filtration application according to the filtering material of the present invention 300 of illustrative embodiments of the invention.The potential filtration application 305 of filter 300 of the present invention except bag type filtering comprises that HVAC filters, and the framework that wherein will have filter medium is put into the passage of air stream to remove for example dust of degranulation from this air before entering the room in this air circulation.It is another kind of the application that Food ﹠ Drink filter, and wherein filter can be placed on before or after the fluid contact drink manufacturing material to remove pollutant from this fluid.Coalescence filtration is another application, for example is used for Diesel engine and marine vessel applications.Other potential filtration application comprises that vacuum filter, demist, turbine inlet air filtration, automobile and truck transmission and air intake filtration, coolant filtration, chemicals filter (comprising that medicine and medicine filter), generating is filtered (power generation filtration), office equipment filtration, paper machine, cloth felt and drain layer and filtered and any other similar filtration application.
Referring now to Fig. 4, this accompanying drawing show an exemplary according to the present invention shown in Fig. 1 from fluid, the method 400 of filtering particle in the hot gas for example.Step 405 is first steps of the technique 400 of filtering particle from fluid, wherein makes non-woven layer 14 by fibre blend.In an exemplary, peripheral layer 14A, the 14B of this filter are preferably made by supatex fabric, this supatex fabric be flame resistance and made by the fibre blend that comprises amorphous silica fibres and at least a fiber that is consisted of by fire-retardant (FR) fiber.
Next, in step 410, non-woven layer 14A, 14B can become by acupuncture manipulation and be connected with woven scrim 202 on every side, as shown in Figure 2.This woven scrim 202 can be by any can standing the desired physics of described material (for example glass fibre) to be required and in about any scrim of making of the material of 2.5osy (ounce per square yard) preferably aspect the weight.This step is chosen wantonly.This non-woven layer 14A, 14B can not be connected with weaving layer or any other type layer, and do not break away from the scope of the invention.
Next, in step 410, this non-woven layer 14A, 14B and scrim 202 can be sealed supporting construction such as wire cage 26, as shown in Figure 2.This step also be choose wantonly and can how be used for specific filter operation according to this periphery non-woven layer 14A, 14B and change.In some cases, peripheral layer 14A, 14B can not seal supporting construction, such as wire cage 26.
Next, in step 420, gained filtration 10 for example places like that the fluid streams 20A that comprises particulate matter 16 and flows along first direction shown in Fig. 1.This fluid streams 20A or particulate matter 16 (or both) can be very hot for example to be about 900 ℃ and can not cause that this filtration becomes and catch fire.
In step 425, particulate matter 16 can be filtered or remove from the fluid streams 20A that flows along first direction.Next, in step 430, expulsion particulate matter 16 cleans this filtration 10 from this filtration 10 by fluid streams (usually second fluid material stream 20C) is moved along the second direction opposite with the first direction of first fluid material stream 20A.Then this technique finish.
Physical property
Supatex fabric mixture of the present invention preferably can satisfy the high request condition of a series of industrial filtration applications, and in a preferred exemplary, can satisfy following physical test requirement:
Weight (osy) ASTM D-5261＜20osy
Gas permeability ([email protected] " water) ASTM D-737-69 20-60
Hot strength (lb.) (ASTM D-4632＞150 * 100 of MD * CD)
Maron BURSTING STRENGTH ASTM D-3786＞300psi
MIT flex stiffiness ASTM D-2176-69＞20,000 circulations
900 ℃ of nothings of anti-strong nut spark are caught fire
(hot?nut?spark?resistance)
400 °F of shrinkage factor@after 2 hours＜2%.
Heat resistance (continuously/peak value) °F 464/500
According to an exemplary, described filter medium can comprise the Maron BURSTING STRENGTH greater than about 500psi.According to another exemplary, described filter medium has the anti-strong nut spark (without catching fire) that is equal to or greater than 900 ℃.According to another exemplary, described filter medium can comprise about 450 °F or larger continuous temperature tolerance.
In alternative exemplary, fabric of the present invention satisfies in the following physical test condition one or more:
Weight-greater than 10,11,12,13 or 14osy, and less than 30,25,20,18,17,16 or 15osy.
Gas permeability-greater than 15 or [email protected] " water, and less than 80,60,50 or [email protected] " water.
Pore volume % (DIN 53855)-greater than about 60,65 or 70%, and less than about 85,80 or 75%.
Hot strength (MD)-greater than about 100,125 or 150, and less than about 250,200 or 180.
Hot strength (CD)-greater than about 60 or 80, and less than about 200,150 or 125.
Anti-strong nut spark (without catching fire)-greater than 500,600,700,800 or 900 ℃.
In the shrinkage factor after 2 hours under 400 °F-less than 5,4,3 or 2%, and greater than 0.2 or 0.5%.
Temperature tolerance (continuously)-greater than about 300,325,350,375,400,425,450 or 500 °F.
Temperature tolerance (peak value)-greater than about 300,325,350,375,400,425,450 or 500 °F.
According to an exemplary, described filter medium has the fabric weight of about 17 ounce per square yard of about 12-(osy).According to another exemplary, described filter medium has the gas permeability ([email protected] " water) of about 20-about 40.
In a preferred exemplary, limit temperature tolerance with respect to the specific support fiber that is attached to silicon dioxide fibre in the fabric, as listed in the following table 6:
Table 6
Embodiment
In order to confirm the effect according to various fibre blends of the present invention, prepare many samples and test, as described below.Provide embodiment to come proved invention practice and should not be construed to limit the present invention or its practice.To how show in the time of in the simulating flame of fabric on being exposed to this fabric of studying the filtration fabrics of 50/50 mixture that relatively comprises silicon dioxide fibre and other high temperature fiber and only being made by high temperature fiber.Following simulating flame: place and to be heated to 900 ℃ 12.7mm diameter metal nut and to allow it to rest on this fabric upper 30 second.Then record this flame from the time of putting out cost.Each test repeats 3 times.The fabric that uses in each case about 16oz/sq.yd that weighs.Unless stipulate that in addition all fabrics that use in the test are Nomexs.
The percentage of each data that obtain from test and mean value and fray-out of flame time of obtaining by the mixed silica fiber reduces and illustrates at table 7 subsequently.By silicon dioxide fibre is mixed with Nomex or PPS fiber, the fray-out of flame time can reduce surpass 50% so that this mixed goods show the same well with more expensive P84 fabric.The minimizing of the fray-out of flame time that can obtain by mixed silica fiber and P84 fiber is very little.
Table 7
Fabric mixture
The data of report provide the more data of contrast property for silicon dioxide fibre mixed goods and the commercial high temperature bag filter fabric with various chemical compositions in the table 8.Clearly, the silicon dioxide fibre mixed goods has the minimum fray-out of flame time: the fray-out of flame time of this mixture changes between second at 4.0-6.4, and the fray-out of flame time of the commercial fabric of non-mixing of eliminating P84 fabric is 9-27.4 second.Should be noted that the employed E-glass-based of this paper fabric comprises proprietary immersion coating with improvement chemical-resistant and/or wearability, and all silicon dioxide fibre base mixed goods do not have any immersion coating.
Table 8
The FR performance
Therefore, obviously in the fabric that hot gas filtration is used the use of amorphous silica fibres be highly effective.The present invention can be by with amorphous silica fibres and at least a other fire resistance fibre, or binder fiber makes up to put into practice, and still not necessarily is limited to this.Practice also being not limited to select specific FR fiber or binder fiber, as long as these one or more selected fiber is made up with amorphous silica fibres.In addition, this fabric is not limited to the supatex fabric type.
In whole application, with reference to various publications.It is for reference to describe the prior art that the present invention relates to more fully that the disclosure of these publications is introduced the application accordingly in full.It will be apparent for a person skilled in the art that in the situation that does not break away from the scope of the invention or spirit and can make various modifications and variations to the present invention.By considering specification of the present invention disclosed herein and practice, other exemplary of the present invention will be apparent for a person skilled in the art.Wish that it only is exemplary that specification and embodiment should think, true scope of the present invention and spirit are illustrated by following claims.
Claims (17)
1. the nonwoven filter media that comprises fibre blend, wherein said mixture comprise amorphous silica fibres and at least a fire resistance fibre, and wherein said amorphous silica fibres comprises the silica of 94-96wt%, the Al of 3-4wt%
2O
3, 0.1-1.0wt% Na
2The CoO of O, 0.01-1.0wt% and the SO of 0.01-1.0wt%
3
2. the nonwoven filter media of claim 1 also comprises two peripheral layers and internal layer, and wherein said internal layer comprises scrim, and wherein said peripheral layer comprises the fibre blend that contains amorphous silica fibres and at least a fire resistance fibre.
3. the nonwoven filter media of claim 1, wherein said mixture comprises the amorphous silica fibres of 20-80wt%, with at least a fire resistance fibre of 20-80wt%, this fire resistance fibre is selected from modified polyacrylonitrile, the polyester of phosphorous heterocycle pentane, melamine, meta-aromatic polyamide, the contraposition aromatic polyamide, polybenzimidazoles, polyimides, polyamidoimide, the polyacrylonitrile of partial oxidation, novoloid, poly-(to phenylene Ben Bing Er oxazole), poly-(to the phenylene benzothiazole), polyphenylene sulfide, anti-flaming viscose artificial silk; The viscose rayon yarn of silicon aluminate improved silica, cellulosics, polyether-ether-ketone, polyketone, PEI, the natural or synthetic fibers that scribble flame-retarded resin or their mixture.
4. the nonwoven filter media of claim 1, wherein said mixture comprises the amorphous silica fibres of 5-65wt% and at least a fire resistance fibre of 35-95wt%.
5. the nonwoven filter media of claim 1, wherein said at least a fire resistance fibre comprises polyphenylene sulfide.
6. the nonwoven filter media of claim 1, wherein said at least a fire resistance fibre comprises aromatic polyimide.
7. the nonwoven filter media of claim 1, wherein said nonwoven filter media is acupuncture.
8. the bag filter that comprises nonwoven filter media, described nonwoven filter media comprises the fibre blend that contains silicon dioxide fibre and at least a fire resistance fibre, and wherein said silicon dioxide fibre comprises the silica of 94-96wt%, the Al of 3-4wt%
2O
3, 0.1-1.0wt% Na
2The CoO of O, 0.01-1.0wt% and the SO of 0.01-1.0wt%
3
9. the bag filter of claim 8, wherein said filter medium is acupuncture.
10. the bag filter of claim 8, wherein said filter medium has the fabric weight of 12-17osy.
11. the bag filter of claim 8, " the gas permeability that has 20-40cfm under the water detection method that wherein said filter medium is at [email protected].
12. the bag filter of claim 8, wherein said filter medium have the Maron BURSTING STRENGTH greater than 500psi.
13. the bag filter of claim 8, wherein said filter medium have anti-strong nut spark and catch fire without any under 900 ℃.
14. the bag filter of claim 8, wherein said filter medium have the continuous temperature tolerance greater than 450 °F.
15. the method for filtering particle from fluid, it comprises:
The filter that comprises fibre blend is provided, and described mixture comprises amorphous silica fibres and at least a fire resistance fibre, and described amorphous silica fibres comprises the silica of 94-96wt%, the Al of 3-4wt%
2O
3, 0.1-1.0wt% Na
2The CoO of O, 0.01-1.0wt% and the SO of 0.01-1.0wt%
3Mixture; With
This flow is crossed described filter.
16. the method for claim 15 also comprises described filter is installed on the wire cage.
17. the method for claim 15 also comprises described filter is installed on the rigid cage.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US80874706P | 2006-05-26 | 2006-05-26 | |
| US60/808,747 | 2006-05-26 | ||
| PCT/US2007/069744 WO2007140302A2 (en) | 2006-05-26 | 2007-05-25 | Hot gas filtration fabrics with silica and flame resistant fibers |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101489656A CN101489656A (en) | 2009-07-22 |
| CN101489656B true CN101489656B (en) | 2013-02-13 |
Family
ID=38779373
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2007800262341A Expired - Fee Related CN101489656B (en) | 2006-05-26 | 2007-05-25 | Hot gas filtration fabrics with silica and flame resistant fibers |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US8211195B2 (en) |
| CN (1) | CN101489656B (en) |
| CA (1) | CA2653445C (en) |
| HK (1) | HK1134055A1 (en) |
| WO (1) | WO2007140302A2 (en) |
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Also Published As
| Publication number | Publication date |
|---|---|
| WO2007140302A3 (en) | 2008-03-20 |
| HK1134055A1 (en) | 2010-04-16 |
| CA2653445A1 (en) | 2007-12-06 |
| WO2007140302A2 (en) | 2007-12-06 |
| US20090301304A1 (en) | 2009-12-10 |
| US8211195B2 (en) | 2012-07-03 |
| CN101489656A (en) | 2009-07-22 |
| CA2653445C (en) | 2015-10-06 |
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